Vulcan 900 Trike Build

[burkbuilds]

Well, I finally got started with my conversion of my 2012 Vulcan 900 to a trike this weekend. I'm still hobbling around a bit so I'm kinda slow and it will probably take me a couple of months to finish but as they say, "every journey starts with one step". I'll try hard to continually update as I make progress with both pictures and some text.

The Fiberglass body and the axle came in by freight. They were strapped down to a large wood pallet and the axle was extremely well protected in a welded steel cage of 1 x 1 angle and then wrapped in cardboard. The fiberglass body was just strapped to the pallet and received a few scrapes from the shipping company, but nothing seemed to be cracked or hit hard. It would have been nice if they had at least put some cardboard around it.

http://s7.postimage.org/n5tc5llwn/Trike_Converstion_Part_1_008.jpg (http://postimage.org/image/n5tc5llwn/)


http://s15.postimage.org/df2y5m9qf/Trike_Converstion_Part_1_007.jpg (http://postimage.org/image/df2y5m9qf/)

http://s15.postimage.org/lymc3di2v/Trike_Converstion_Part_1_005.jpg (http://postimage.org/image/lymc3di2v/)
Here is a pic of the steel support structure that holds up the Fiberglass section.


http://s7.postimage.org/ckruck947/Trike_Converstion_Part_1_010.jpg (http://postimage.org/image/ckruck947/)

The Trike Axle is from DNA Specialties, they make axles for a lot of different companies. They did an amazing job of protecting the axle with a steel cage for shipping.


http://s8.postimage.org/b4tbpsu9t/Trike_Converstion_Part_1_013.jpg (http://postimage.org/image/b4tbpsu9t/)

http://s13.postimage.org/a9ng0icmb/Trike_Converstion_Part_1_018.jpg (http://postimage.org/image/a9ng0icmb/)
The Axle has dual disk brakes:


http://s15.postimage.org/rf9lbi0uf/Trike_Converstion_Part_1_019.jpg (http://postimage.org/image/rf9lbi0uf/)

http://s9.postimage.org/wqae0fbu3/Trike_Converstion_Part_1_025.jpg (http://postimage.org/image/wqae0fbu3/)
The swingarm was made by Treasure Coast Trikes. It is very heavy duty and hopefully it will fit just as well as it looks.

http://s17.postimage.org/a6ptvs6zv/Trike_Converstion_Part_1_011.jpg (http://postimage.org/image/a6ptvs6zv/)

http://s17.postimage.org/xm7r14qqz/Trike_Converstion_Part_1_012.jpg (http://postimage.org/image/xm7r14qqz/)

I'm going to quit now and post this much before something happens and I loose all this. I'll add some more pics in a few minutes.

[burkbuilds]

The chrome wheels came from Summit Racing:

http://s14.postimage.org/u4wvev28t/Trike_Converstion_Part_1_009.jpg (http://postimage.org/image/u4wvev28t/)
The Tires are Goodyear Viva II's 215/60/R15


http://s18.postimage.org/ty4xn55h1/Trike_Converstion_Part_1_026.jpg (http://postimage.org/image/ty4xn55h1/)

The kit came with the studs (12mm x 1.5) but no lug nuts, so I bought these at Advance Auto Parts.


http://s8.postimage.org/xnilri6o1/Trike_Converstion_Part_1_022.jpg (http://postimage.org/image/xnilri6o1/)
I installed the studs with red lock tite, I don't want them coming out.


http://s9.postimage.org/vqooigm23/Trike_Converstion_Part_1_024.jpg (http://postimage.org/image/vqooigm23/)
I let the loc tite sit overnight and then put the tires and lug nuts on the next day.

http://s8.postimage.org/8iw6rtwld/Trike_Converstion_Part_1_028.jpg (http://postimage.org/image/8iw6rtwld/)
Once I had the tires on the axle I used a lift to pick up the swingarm assembly and line it up with the attachment blocks on the axle. There's a big hex bolt on each end of the axle where the swingarm locks in to allow you to adjust the tension on the belt.

http://s10.postimage.org/m2aq8gftx/Trike_Converstion_Part_1_027.jpg (http://postimage.org/image/m2aq8gftx/)
I may have to do a 3rd post here this seems to be about all the pics I can load.

[burkbuilds]

I can't seem to add any more pictures right now, not sure why. Maybe I've uploaded my limit tonight.

[burkbuilds]

Here is the bike sitting in front of the assembled axle/swingarm.
http://s13.postimage.org/w4i47vbdv/Trike_Converstion_Part_1_033.jpg (http://postimage.org/image/w4i47vbdv/)
I also ordered a "touring trunk with wrap around passenger backrest" to add to the fiberglass body.


http://s11.postimage.org/mldh5956n/Trike_Converstion_Part_1_016.jpg (http://postimage.org/image/mldh5956n/)
It was not assembled and there are zero instructions, but it wasn't very difficult to puzzle out how to put it together.


http://s10.postimage.org/z7zf61oh1/Trike_Converstion_Part_1_031.jpg (http://postimage.org/image/z7zf61oh1/)

http://s8.postimage.org/b4k4ybfi9/Trike_Converstion_Part_1_030.jpg (http://postimage.org/image/b4k4ybfi9/)

I realized I needed hinges for the main body fiberglass lid, it came with a nice handle and lock, but no hinges, so I've ordered those.

I also had to order tail/stop/brake lights to go on the fiberglass body. I found some oval ones on ebay that were filled with 10 LED's and had a plug in pigtail already wired onto it, I hope that will plug into my wiring harness, but if not I can do some soldering.

Next weekend I guess I will start taking the stuff off the rear of the Vulcan. The bags, sissybar, fender and swingarm all have to come off and probably a few things I haven't even thought of yet. I'll update as I go.

[Water Warrior 2]

Woohoo, you're gettin at er. Excellant pics and descriptions. The axle looks like a fine piece of work with the 2 disks and 5 bolt pattern. Gotta ask though, is there an actual differential or is it a solid axle straight across?

Like the trunk for storage etc. You will have a nice touring rig once it is all together with the rack in place. Looking at the pics I doubt there will be a noticeable weight difference for the engine to pull. Yeah, maybe some but it is a 900cc torque machine you'll be riding.
Looking forward to the next installment. Do be careful and not strain the body parts too much. No pain no gain is a load of crap.
Stupid question time before I forget. Have you ridden the 900 yet? It's gotta be a sweet ride.

[PimpS]

well done burkbuilds! Looks like a well planned and fast make over! Can't wait for more pics and progression!

[jonathan180iq]

Holy shit, those are some pretty pieces.
....There is nothing like new hardware to get the old juices flowing.

[Rookie Rider]

Looking good.

[bpdchief]

Looks like a fun project. Save that metal crate - make a small pull behind for the bike :roll:
Can't wait to see the finished bike with you on it :2tup:

[burkbuilds]

Thanks everyone.
WW, yes the axle has a limited slip differential not just straight through axle. I have ridden the 900 twice for a total of less than 20 miles. It is a really smooth machine and the torque at almost any speed is strong and smooth. The center of gravity is low and it was easy to handle. I really enjoyed my little trip through the Chickamauga battlefield. The added weight of the kit with all the stuff is about 250 lbs net. (You loose some weight from removing the OE swingarm and rear tire assembly. So, basically it should be the equivalent of having a large second rider on board but I thin this bike can handle it with no problem. The 900 is rated at about 45 mpg normally, so I'm hoping to get about 40 mpg when it is converted to the trike.
My painter recommended that I put it all together, drill all the holes, and try everything out to make sure it was how I wanted it and then take the body off and bring it to him to paint, so that is my plan. It's a little more work that way but I think he's given me good advice, especially since I haven't done this before.
This may look like a lot so far, but I really didn't do a lot other than unpack stuff at this point. I realize that I am still recovering from my wreck and although I can now stand and walk slowly without a cane I am by no means fast, nor can I pick up anything heavy and walk with it. So, this may take a while, but that's okay. I'm just happy that I am able to do it at all. :)

I have been back at work for less than 2 weeks and I'm required to be in the wheelchair at work for another 3 weeks, then 4 weeks walking but no lifting. Nice to be earning a paycheck once again.

Hey, I finally finished all the classes I was taking in the Spring when I had my wreck and ended with 3 A's and 1 C, Yea! I have one final left to take for the one class I took this Summer and then 2 classes this Fall and I should graduate in December. I will be so glad to be finished with school. :)

[Water Warrior 2]

Thanks everyone.
WW, yes the axle has a limited slip differential not just straight through axle. I have ridden the 900 twice for a total of less than 20 miles. It is a really smooth machine and the torque at almost any speed is strong and smooth. The center of gravity is low and it was easy to handle. I really enjoyed my little trip through the Chickamauga battlefield. The added weight of the kit with all the stuff is about 250 lbs net. (You loose some weight from removing the OE swingarm and rear tire assembly. So, basically it should be the equivalent of having a large second rider on board but I thin this bike can handle it with no problem. The 900 is rated at about 45 mpg normally, so I'm hoping to get about 40 mpg when it is converted to the trike.
My painter recommended that I put it all together, drill all the holes, and try everything out to make sure it was how I wanted it and then take the body off and bring it to him to paint, so that is my plan. It's a little more work that way but I think he's given me good advice, especially since I haven't done this before.
This may look like a lot so far, but I really didn't do a lot other than unpack stuff at this point. I realize that I am still recovering from my wreck and although I can now stand and walk slowly without a cane I am by no means fast, nor can I pick up anything heavy and walk with it. So, this may take a while, but that's okay. I'm just happy that I am able to do it at all. :)

I have been back at work for less than 2 weeks and I'm required to be in the wheelchair at work for another 3 weeks, then 4 weeks walking but no lifting. Nice to be earning a paycheck once again.

Hey, I finally finished all the classes I was taking in the Spring when I had my wreck and ended with 3 A's and 1 C, Yea! I have one final left to take for the one class I took this Summer and then 2 classes this Fall and I should graduate in December. I will be so glad to be finished with school. :)
A limited slip diff, nifty and probably a good idea overall. I like the painters advice, basically he is wanting you to prefit and iron the kinks out instead of munching his paint job.
Congrats on the good marks and continuing education program.

[burkbuilds]

I spent about 5 hours earlier this week on two evenings working on stripping the items off the bike. I removed the seat and the backrest and saddle bags.

http://s9.postimage.org/5ukqb0d0b/Trike_Conversion_Update_1_008.jpg (http://postimage.org/image/5ukqb0d0b/)
Next I put the bike up on a lift I bought at Harbor Freight. With my limited range of motion getting up and down this lift was pretty much essential for me.


http://s17.postimage.org/57pd3uku3/Trike_Conversion_Update_1_009.jpg (http://postimage.org/image/57pd3uku3/)
Next I removed the tail lights and license plate assembly and the rear fender.


http://s15.postimage.org/6o6w8y9fr/Trike_Conversion_Update_1_010.jpg (http://postimage.org/image/6o6w8y9fr/)
I was hoping to leave the exhaust pipes alone, but I just couldn't get to all the swing arm bolts with it in place so off the pipes came.


http://s10.postimage.org/cf261f66d/Trike_Conversion_Update_1_011.jpg (http://postimage.org/image/cf261f66d/)

http://s13.postimage.org/nfu09xg5f/Trike_Conversion_Update_1_012.jpg (http://postimage.org/image/nfu09xg5f/)
Now I was able to get the rear tire assembly out.


http://s10.postimage.org/mrognhzph/Trike_Conversion_Update_1_013.jpg (http://postimage.org/image/mrognhzph/)

http://s10.postimage.org/eoqac6f45/Trike_Conversion_Update_1_022.jpg (http://postimage.org/image/eoqac6f45/)
Here is how it looks from the back with the wheel out of the way.

http://s16.postimage.org/um7uts7c1/Trike_Conversion_Update_1_014.jpg (http://postimage.org/image/um7uts7c1/)
I took the brake caliper off and just secured it to the frame for the time being to get it out of the way.

http://s14.postimage.org/tbh3i5qfh/Trike_Conversion_Update_1_015.jpg (http://postimage.org/image/tbh3i5qfh/)
On the drivers side I needed to move the radiator overflow bottle to gain access to the swing arm bolts.
http://s14.postimage.org/49ek5bk0d/Trike_Conversion_Update_1_016.jpg (http://postimage.org/image/49ek5bk0d/)
Next I got the mono shock absorber out
http://s18.postimage.org/tygiegr11/Trike_Conversion_Update_1_021.jpg (http://postimage.org/image/tygiegr11/)
Finally I was able to remove the bolts holding the swing arm assembly in place and pull it out.

http://s14.postimage.org/oppknjua5/Trike_Conversion_Update_1_017.jpg (http://postimage.org/image/oppknjua5/)
Here is a pic of the bike from the back without the swing arm in place
http://s8.postimage.org/h86t2re9t/Trike_Conversion_Update_1_018.jpg (http://postimage.org/image/h86t2re9t/)
The new swingarm needed the shock mount assembly from the one I pulled out of the bike, so I removed it from the bike swing arm and installed it on the trike kit swing arm.
http://s12.postimage.org/bycrx2ps9/Trike_Conversion_Update_1_019.jpg (http://postimage.org/image/bycrx2ps9/)

http://s12.postimage.org/4kxdy45qh/Trike_Conversion_Update_1_020.jpg (http://postimage.org/image/4kxdy45qh/)
Once I had the swingarm out on the ground next to the trike kit, I realized the trike kit company just bought a swingarm for a Kawasaki Vulcan 900, cut two parts of the frame off it and welded it to the Trike Kit Axle Assembly with some thick plate steel. Pretty smart way of doing this actually.

[Water Warrior 2]

WOW !!!! That is an awesome amount of work you have done so far. The beauty of doing a new bike is no rust, mud, slime or screwed up fittings. I used to undress my new dirt bikes years ago to see what was under the plastic but you Sir have gone way beyond anything I ever did. BB, you did an amazing start in only a few hours and I am more than impressed.

A suggestion though. For my peace of mind. Please please please cover the tank with a couple fluffy towels to protect the finish. Tools and shiny paint will eventually get attracted to each other. It is a Universal Law. :oops: :poorbaby:

[mole2]

Very good progress there BB. I really like that jack from Harbor Freight - much better than the one I bought from them.


:)

[alantf]

Lovely job. One question, though. How do you get a belt drive fitted to the diff. without taking the axle, & diff. covers, off the swingarm? :)

[jonathan180iq]

This is a gorgeous thread.
Mechanic porn

[Water Warrior 2]

This is a gorgeous thread.
Mechanic porn
And fondling the new parts is a requirement. We get to watch and it is not considered bad. Life is good. :2tup:

[burkbuilds]

Hi Alantf, I actually got that all put together last night in about two hours and I have pics, but I'm tired and ready to crash tonight, so I'll try to post tomorrow.

I came home from dinner tonight to find that we had a flash flood in the area and my shop got about 8" of water in it, so I've spent the last several hours trying to clean and dry out everything. Got about 5 or 6 fans running now trying to get all the dampness out of the nooks and crannies and hopefully I will be able to work on the bike the rest of the weekend. A ditch up the road was clogged up causing the water to go up and over the road bed and down my neighbors driveway across my back yard and straight through my garage door and into my shop. Bummer. This has happened before. I think it's time to build a 12" high dam across my property line.

[Maggie]

Wow, so great to see all the pics. It's like seeing an xray to learn what's really under the flesh. Thanks BB. I'm too chicken to really take things apart, so I really appreciate the visual.

[PimpS]

Yiha! Way to go BB!

[burkbuilds]

Saturday was spent mainly cleaning up my shop after the flash flood of Friday night. We officially had 1.5" of rain in 30 minutes. I was out to dinner with my wife when the storm hit and on our way home I saw several roads underwater that I've never seen underwater before. When we arrived home I immediately went back to my shop in our backyard and found water marks up to 8" high. My floor slopes towards the doorway and even at the back of the shop I had 4" of water. Well, thanks to shop vacs, floor fans and low humidity weekend, I have pretty much dried my shop out now. So I got to spend about 6 hours this weekend working on the Trike build and I got a lot done.
I was able to get the rear axle all lined up and welded in place. The rear brakes are connected and bled out and I put a lot of the covers and stuff back in place. I also figured out how the support stuff for the fiberglass body kit needs to be mounted, although I'm going to have to do some welding to make it work, at least I got it figured out.

I took lots of pictures today, but I'm worn out, so I will try to post them when I get home tomorrow.

[alantf]

Welding? I thought a "kit" meant that you just removed old parts, then fixed ready made new parts to the bike. :??:

[alantf]

I came home from dinner tonight to find that we had a flash flood in the area and my shop got about 8" of water in it

We could do with some of that. There's fires raging across the island, and with all the reservoirs dried up, the helicopters can't find anywhere to scoop up water with their buckets. Luckily we don't live in the tree line, but it's worrying. (put a thermometer on the table on the patio, & it's 110º, so no chance of rain)

[burkbuilds]

Alantf, sorry to hear about the fires in your area. Wish I could send some of our rain your way. I hope you are able to avoid any losses.

Okay, I promised more pictures.
Sunday I had to get the mono shock in place. It wasn't very difficult except that I just don't bend very well yet. Fortunately, the motorcycle lift made it possible to get everything in a place I could get to. Once I got that attached I felt like I was ready to start adjusting the belt and axle stuff. I got it all on but when I turned the belt I could hear a "roar", not good. My first thought was that I hadn't gotten something back together in the differential correctly, but I soon realized that the belt was rubbing on the top of the housing. Also not good because no matter how I pivoted it, there just wasn't enough clearance in the housing for the belt not to rub. So, I took it all apart.
http://s17.postimage.org/bao6w6ztn/Trike_Conversion_Update_3_007.jpg (http://postimage.org/image/bao6w6ztn/)

http://s7.postimage.org/xvozl3x47/Trike_Conversion_Update_3_010.jpg (http://postimage.org/image/xvozl3x47/)

http://s12.postimage.org/5d5ke37k9/Trike_Conversion_Update_3_022.jpg (http://postimage.org/image/5d5ke37k9/)
Once I had it apart I started checking things out and I found that my old sprocket was 12" in diameter, the one in the kit is 12-1/2" in diameter. I think if it had been 12" it would not have a clearance problem. My first thought was to swap them, but the bolt pattern was different and the center hole in the kit was larger and the sprocket had about a dozen drilled and tapped holes where the carrier attached to it. So I decided to open up the housing. First I tried to file enough away, but that was slow going.

http://s17.postimage.org/iocrmmymz/Trike_Conversion_Update_3_020.jpg (http://postimage.org/image/iocrmmymz/)
So I finally got serious and cut about a 1/4" off the housing and then filed it down smooth. No more interference.

http://s12.postimage.org/8izcvs4y1/Trike_Conversion_Update_3_023.jpg (http://postimage.org/image/8izcvs4y1/)
Next I got it all back together and started getting it lined up with the front sprocket.

http://s12.postimage.org/vcsb50tmx/Trike_Conversion_Update_3_006.jpg (http://postimage.org/image/vcsb50tmx/)
Once I felt confident about proper alignment I prepped the axle for some welding of the blocks that hold everything in alignment.
http://s9.postimage.org/gbd8w118b/Trike_Conversion_Update_3_028.jpg (http://postimage.org/image/gbd8w118b/)

http://s17.postimage.org/bsx4h9tjv/Trike_Conversion_Update_3_029.jpg (http://postimage.org/image/bsx4h9tjv/)
I stick welded both pieces and then cleaned the welds and spray painted with a high gloss enamel Rustoleum.
http://s8.postimage.org/dmjewbgep/Trike_Conversion_Update_3_032.jpg (http://postimage.org/image/dmjewbgep/)

http://s13.postimage.org/dllqtd9dv/Trike_Conversion_Update_3_033.jpg (http://postimage.org/image/dllqtd9dv/)
Now it was time to get those rear disk brakes set up. The kit came with several nice lines and adapters.

http://s8.postimage.org/lhtyb4q1d/Trike_Conversion_Update_3_034.jpg (http://postimage.org/image/lhtyb4q1d/)

http://s12.postimage.org/7e5aqeih5/Trike_Conversion_Update_3_037.jpg (http://postimage.org/image/7e5aqeih5/)

http://s11.postimage.org/egwog1klr/Trike_Conversion_Update_3_036.jpg (http://postimage.org/image/egwog1klr/)
Unfortunately, the banjo's were to long to use, they would hit the inside of the wheel, so I made a trip to the local auto parts store and bought some short brake lines I could bend to fit.
http://s9.postimage.org/fgzw1h857/Trike_Conversion_Update_3_045.jpg (http://postimage.org/image/fgzw1h857/)
It took a little work to get everything tied in and bleed the calipers but it wasn't really difficult.


http://s8.postimage.org/7a8v082q9/Trike_Conversion_Update_3_042.jpg (http://postimage.org/image/7a8v082q9/)
Finally it is time to start putting stuff back in place. The radiator overflow bottle and then the side covers on that side came next.

http://s13.postimage.org/4l3tnbq2r/Trike_Conversion_Update_3_044.jpg (http://postimage.org/image/4l3tnbq2r/)
Here is a shot of the bike sitting on the floor waiting for me to figure out the exhaust and the supports for the fiberglass body.
http://s12.postimage.org/g5lic5gjt/Trike_Conversion_Update_3_046.jpg (http://postimage.org/image/g5lic5gjt/)

http://s17.postimage.org/t2n8qqf2z/Trike_Conversion_Update_3_047.jpg (http://postimage.org/image/t2n8qqf2z/)
Finally, I set the seat in place to help me get an idea for the height I need when I attach this "universal" bracket to hold up the fiberglass kit.
http://s14.postimage.org/6fc4esfm5/Trike_Conversion_Update_3_048.jpg (http://postimage.org/image/6fc4esfm5/)

http://s11.postimage.org/rjwwd207j/Trike_Conversion_Update_3_051.jpg (http://postimage.org/image/rjwwd207j/)

[Water Warrior 2]

OMG, this is killing me. I can't wait to see the finished product.

[PimpS]

Wicked! Even though i don't like to drive trikes, they sure, i mean yours will really look nice, kind of chumpy and i like that. All the trikes i see on our roads are also mainly done at home of bikers and their engine is mainly took out of the good old volkswagen beatle, made with those long forks. Driving a 3 wheeler (1 front, 2 back) gives me the creeps when going into curve (but that's only my experience with the bikes i use to drive at my former work with kids with special needs). Well done BB, it really is a mechanic porn you're showing us! ;)

[alantf]

Once I had it apart I started checking things out and I found that my old sprocket was 12" in diameter, the one in the kit is 12-1/2" in diameter. I think if it had been 12" it would not have a clearance problem. My first thought was to swap them, but the bolt pattern was different and the center hole in the kit was larger and the sprocket had about a dozen drilled and tapped holes where the carrier attached to it. So I decided to open up the housing. First I tried to file enough away, but that was slow going.





Have you been in touch with the manufacturers, to find out why they've made a mistake? They may not be aware of their error. :)

[Water Warrior 2]

Once I had it apart I started checking things out and I found that my old sprocket was 12" in diameter, the one in the kit is 12-1/2" in diameter. I think if it had been 12" it would not have a clearance problem. My first thought was to swap them, but the bolt pattern was different and the center hole in the kit was larger and the sprocket had about a dozen drilled and tapped holes where the carrier attached to it. So I decided to open up the housing. First I tried to file enough away, but that was slow going.





Have you been in touch with the manufacturers, to find out why they've made a mistake? They may not be aware of their error. :)
I doubt the larger sprocket is an error. It may have been a means of retaining the original factory gearing with the different wheels on the back. Or possibly to change the gearing a bit to compensate for the extra weight of the entire machine after assembly. The small opening for the belt is odd but BB cured that quickly enough.

[alantf]

It was the belt opening that I was referring to. It's odd that the clearance was wrong. I'd have thought that they'd have put one together before marketing it, and found their mistake.

[burkbuilds]

Lol WW, I'm going as fast as I can, which is pretty slow. I also have classes starting Wednesday night, so depending on how much work these last two classes throw my way it might get even slower. However, last night I was able to figure out how to make the bracket work to hold up the fiberglass. I had to cut away a lot of the stuff that came on it, and weld a couple of pieces of 1/4" x 2" flat stock in the right places to allow me to hopefully bolt it onto the bikes existing frame. I got it all painted and I'm heading out to the shop now to start putting it on the bike. More pics soon.

Oh, Alantf, I have not contacted them yet but I bet the rear end housing is pretty much a universal fit for a variety of bikes and although it was annoying to have to take the time to modify it, no big deal. WW has a point, they may also have increased the size of the rear sprocket to give me a little more torque to compensate for the added weight from the trike kit. Alan, like you, I did not expect to have to do this much welding. Fortunately, I have the tools and training to do it, but if I did not have those abilities and tools I would have been very frustrated.

[burkbuilds]

I ran into some fitment problems tonight getting the fiberglass body and everything to line up. Kinda looks like the axle needs to slide back a few inches and the only way that will happen is 1. Buy a longer drive belt, or 2. Replace the oversize pulley with one that matches the OEM diameter. I've sent pictures and questions to the kit supplier. I hope they have a quick and painless solution.

Here's pics of the problem:
http://s18.postimage.org/g4jfhsdlx/Trike_conversion_Update_3_004_2.jpg (http://postimage.org/image/g4jfhsdlx/)

http://s15.postimage.org/rp0akmk07/Trike_conversion_Update_3_005_2.jpg (http://postimage.org/image/rp0akmk07/)

http://s17.postimage.org/8p73521ff/Trike_conversion_Update_3_006_2.jpg (http://postimage.org/image/8p73521ff/)
The last picture shows it best. The wheel wells are touching the front edge of the tires and there is a large space behind the tire plus the seat is still not down as it should be and the touring trunk is hanging off the rear of the fiberglass base way to far.

I checked the pulley diameter difference again and it's over an inch different which makes the circumference over 3" difference which just might be the entire problem. It would actually be simpler to put a longer belt on it than to swap the pulley out for a smaller one at this point but I'm sure nobody is going to want to buy me a new belt and they might swap out the pulley. I guess I'll have to wait and see.

[Water Warrior 2]

Hmm. Is there enough adjustment to the rear end assembly to move it back the required distance? Hopefully the manufacturer has a solution.

[burkbuilds]

I got a short reply from the company I purchased the kit from today. Basically, they are in Sturgis and they'll call me when they get back but they did not offer any real advice other than, "obviously, the axle is to close to the body of the bike", duh. So I called DNA, the company that actually manufactured the axle and talked with a very nice and knowledgeable representative. He told me that the axle is designed for Harley's and not any other bikes and the last time they sold a smaller pulley was in 2007 and they didn't sell well so they discontinued them. He was very nice and offered to contact a shop and provide them with the old specs for that pulley and get a price for me to have one made although he warned me that it would be very expensive in his opinion. I'm supposed to call him back tomorrow for an update.

I also spent over an hour at my local Kawasaki dealer this afternoon where they helped me look on line and in manuals for a longer belt that would work, but apparently, the belt on my 900 is about as long as they make one. I'm a little frustrated at this point and basically I don't think there is going to be a satisfactory solution that won't cost me a chunk of change. So, unless someone surprises me with a no cost or low cost solution I think I'm going to modify what I was planning and do this a little differently. I like the DNA axle and the brakes and tires are exactly what I want. I also like the touring trunk and I really wanted the fiberglass body but I don't think that is going to fit. So, I think I will probably try to send the body back for a refund, keep the axle set up and put my OE body parts back and add the trunk somehow. I've mocked it up a little tonight although I'll have to get some nice chrome fasteners and stuff to make it work and then add some stand alone fenders and go back with some saddle bags that will fit between the fenders and the bike. (The OE ones are to big to fit).
Here's what I have so far to give you an idea of where I think I'm going with this.

http://s9.postimage.org/y7wrf0otn/Trike_build_Update_5_002.jpg (http://postimage.org/image/y7wrf0otn/)

http://s12.postimage.org/5rz0ia0nd/Trike_build_Update_5_001.jpg (http://postimage.org/image/5rz0ia0nd/)

http://s18.postimage.org/8niwn21o5/Trike_build_Update_5_003.jpg (http://postimage.org/image/8niwn21o5/)

http://s10.postimage.org/6ja2jnrt1/Trike_build_Update_5_004.jpg (http://postimage.org/image/6ja2jnrt1/)

[Maggie]

Hmmm...think I like this look a little better!

[Water Warrior 2]

Here's hoping they take the body back. Fingers crossed.
Stand alone fenders may be a good solution to your dilema. Paint them the same as the center fender and it would likely be real neat and classy looking. Suitable bags and the trunk will make it a one of a kind touring rig.
Just letting my mind do some wandering. Barring the cost of course, would it be possible to use the body work as the basis for a trailer? It might be a lot of work but it sure would look neat.

[alantf]

Just thinking aloud.......... Over here I've seen various trunk options fitted to quadbikes. You might like to search online to see if there's anything for you. :)

[burkbuilds]

I talked with DNA again today. They were not able to find anyone willing to make me a one of a kind pulley. We also talked about the difference in offset side to side vs the Harley bikes this axle was designed for and when I measured the distance between the inside of the tires and the frame of my bike there is a 3" difference (about 76mm for anyone outside the US). Which means that the axle needs to slide 1-1/2" back to the right to be perfectly centered, but if I do that the sprocket won't line up. So, I'm even more frustrated with the whole thing now. I've sent two more e-mails to the company I bought the kit from asking if they have solutions for these problems but so far no reply. :??:

[Water Warrior 2]

So they say the axle was designed for a H-D. Get it in writing and you have a reason for a full refund. Sounds like they were hoping you would put up with a lop sided trike kite. Close only counts in horseshoes, bikes need to be very exact to work properly and safely. They did not do their home work very well.

[mole2]

If you payed with a credit card stop the payment. That will get attention. Being as the rear assembly is not for your bike they will have to give a full refund at that point and pay the return shipping or they don't get it back. That's the reason I pay for EVERYTHING with my cc. Plus the points. :)


:)

[fatoldfool]

Right on that credit card; this is just too sloppy to let go...sounds to me like someone just wanted some money fast and did NOT do any engineering....at any rate is poor business, and they should not be let by with it.....I wish you luck!...

[burkbuilds]

I finally got some replies from the company I bought the kit from. They basically admitted that they haven't put this kit on a Vulcan 900 before when they responded that they were going to "contact other trike builders to ask them how they handled these problems". They initially said they would find a longer belt, but in a later e-mail replied that they were not able to find a longer one. Between something they said and some research I did I was able to pretty much find a solution to resolve the side to side balance issue. I've ordered wheels with different backsets from Summit. The left wheel will set in toward the frame more than the current wheel and the right wheel will set out from the frame further. I will also add a 1/2" spacer to the right wheel to put it out even further and that will bring me to within 1/2" of perfectly symmetrical side to side. I don't think a 1/2" will be visually noticeable. I'll put fenders over the wheels and weld on some support brackets to hold them securely and have them painted to match the color scheme of the rest of the bike. I think that will look okay. I'm going out to my shop today to make some brackets that will allow me to mount the touring trunk behind the passenger seat. I'll get some saddle bags to fit between the fenders and the center frame of the bike, the ones that came with my bike are to wide to fit.

I've requested that the kit supplier take back the fiberglass kit and the wheels they sold me that won't work with my bike and fully refund that part of my purchase. Hopefully they will honor that request. If not I may look into doing something like WW suggested and make that kit and the wheels into a pull behind trailer or something. If they do not then I will at least file a complaint with the BB bureau and post warnings all over the internet not to deal with them. You may have noticed that I haven't named them in any of my posts yet. Hopefully though the kit supplier will do the right thing and refund that part of my purchase. I recommended to the kit supplier that they should change their advertising and not tell anyone this kit will work with the 900, at least not with the body kit and the wheels they are selling. I did pay with a CC and I'm sure I could send everything back and fight those charges, but I want a trike, I've put a lot of time into it so far and I'd rather just try and make the best of a less than perfect situation.

I'll let you know how they respond to my request for a partial refund of the parts I can't use. If they work with me on that they I probably will not seek any other action against them. If they refuse to honor that request that will change.

[mole2]

Personally I'd make them take the whole thing back rather than jury rig the setup. Plus they pay the return shipping as well as a full refund. At that point all you've lost is the time you put in. If they don't cooperate then take them to court.

What about looking at one of these? MTC Voyager Motorcycle Conversion Kit (http://www.mtcvoyager.com/). The nice thing about those is it's an on and off setup (4 wheels) which allows you to ride as a trike or on two wheels. In fact the Ultra looks like what you're trying to do now. They have the Vulcan 900 listed. Watch the video here (http://www.mtcvoyager.com/home/voyager-video.html).

Looking on Ebay you can pick up a used kit for cheap. You just have to have the proper frame kit. You can look your frame kit up on MTC Voyager and see what other motorcycles use the same kit.

Voyager kits on Ebay (http://motors.shop.ebay.com/i.html?_nkw=voyager+trike+kit).


:)

Edit to add Ebay info

[Water Warrior 2]

I've put a lot of time into it so far and I'd rather just try and make the best of a less than perfect situation.


Gotta hand it to you BB, you don't give up easily. The offset wheels are brilliant. I never would have thought of it. Hopefully the supplier will do the absolute best to resolve the situation and support you for the time you have spent developing their product. At least they appear to be upfront when admitting to never having actually done a 900 to full completion.
From the sounds of it they are in the trike industry for the long haul. Bringing the other competitors into the scene shows their commitment to keep the whole aftermarket in a good light to all potential customers. Yup, there is a light at the end of the tunnel if only you reach for it.

[burkbuilds]

Mole, thanks for the links, I've looked at that set up before and a lot of people use them but it just doesn't appeal to me personally.

WW, thanks for the encouragement. I'm feeling better about all of it today, especially after I made my brackets and mounted the trunk on the bike. I ordered fenders today and once they come in I'll have some welding and bolting to do to get them ready for the paint shop but basically I'll be finished at that point. I even climbed up on the passenger seat after I got the trunk mounted and it was pretty comfortable. My wife said she'd probably ride 2 up with me on this when it's done. I've tried to get her to ride with me before on two wheels and it just was NOT going to happen.

Here are a few shots of the trunk mounted on the bike and the brackets I made from some checker faced aluminum I had around the shop.

http://s16.postimage.org/rg9fb2nkx/Trike_build_Update_6_004.jpg (http://postimage.org/image/rg9fb2nkx/)

http://s12.postimage.org/94osb3gw9/Trike_build_Update_6_003.jpg (http://postimage.org/image/94osb3gw9/)

http://s10.postimage.org/nii28t84l/Trike_build_Update_6_002.jpg (http://postimage.org/image/nii28t84l/)

http://s9.postimage.org/ik2wtra3f/Trike_build_Update_6_001.jpg (http://postimage.org/image/ik2wtra3f/)

[Water Warrior 2]

Awesome!! You're gonna make it happen. New wheels and fenders will do away with the built in offset nicely.

But I have to ask a question in all seriousness. Slightly off topic but my curiousity is on a high level right now. Why would you have a pallet jack in a home garage????

[burkbuilds]

WW, well, this is a home garage of sorts, but it is also my woodworking shop and I've found that pallet jack to be a wonderful back saver over the years. I paid less than $200 for it new and although I only use it a few times a year, I am always glad I have it when I need it.

Got something of a response from the Trike company today. The owner kinda tried to belittle me and make it sound like I just didn't know what I was doing and that she wouldn't have the same problems if she had this in her shop, but in the end she did agree to refund the money for the fiberglass body if I sent it back to her. She failed to say whether she would do the same with the wheels, so I've sent another e-mail asking for an answer to that. I also took some pictures of the bike from the rear that show how badly offset the entire thing is now, so here they are.

http://s10.postimage.org/s26ah9xxx/Wheel_Offsets_001.jpg (http://postimage.org/image/s26ah9xxx/)

http://s17.postimage.org/llwd721h7/Wheel_Offsets_002.jpg (http://postimage.org/image/llwd721h7/)

http://s17.postimage.org/ey4cy77cr/Wheel_Offsets_003.jpg (http://postimage.org/image/ey4cy77cr/)

She requested that I put the fiberglass body back on and send her pictures to show this but I told her I had already put the OEM fender, seat and made brackets for the trunk and installed it and I wasn't going to pull all that off again just to take a picture for her. I think it is pretty clear that there is 3" of difference in the distance between the tires and the frame from one side to the other.

[Water Warrior 2]

Those 3 pics should be all she needs to make the right decision. Putting the bodywork back on won't hide that much of a discrepancy. Your previous pics of the lack of fit with the bodywork would just confirm your concerns and make your case stronger.

[mrlmd1]

Nice job so far, and a lot of work and dedication.
Here's one, all done.
Get one of these and you'll never have to worry about hitting a friggin' dog or a cage or anything else on the road.
http://s13.postimage.org/3qu1srrtf/3_wheeler.jpg (http://postimage.org/image/3qu1srrtf/)

Can't wait to see yours finished.

[Water Warrior 2]

Sure hope that trike has a power steering assist built into it.

[burkbuilds]

WOW! Now that is a Trike!

I got a call from Summit today, one of the wheels I ordered is no longer made, so I cancelled the other and went back to looking at my wheel options. It actually worked out in my favor. I found a set of nice Chrome wheels with a 3" difference in backset, so now I won't even need the spacer and it will be dead on centered up. The icing on the cake . . . they cost less than the ones I had ordered first so I'll get a few bucks back, and the center caps from my original wheels are the correct size for these wheels. They promised me they would get here by Friday, which would be nice. My fenders are scheduled to arrive this week so maybe I can weld everything up and have it ready to go to the paint shop next week.

[Water Warrior 2]

You must have a golden horse shoe hiding somewhere dark. I'm very happy to hear things are turning around in such a good, glorious, neat, splendid, super, sense of relief kinda way. You will likely go a little bonkers when the bike is out for paint and you have nothing to do except daydream. Maybe just work on a good fantasy for a while.

Will the fenders match the original fender? I think that would be a real eye candy.

[burkbuilds]

WW, yeah, I'll probably be a little anxious, like a kid waiting on Christmas, when it is at the paint shop. The fenders will match in paint scheme but I think I'd have to have them custom made to look like the OEM fender, so no, they will just be plain steel fenders with a rolled edge on the outside lip. I just checked and the fenders are scheduled to arrive tomorrow, the wheels on Friday and some chrome nuts and bolts I ordered also on Friday.
Right now I just need to crack down on my studying and get as much done before the weekend so I'll have weekend time to work on the Trike not spend it studying.

[Water Warrior 2]

That's what I meant to say. Matching paint, not the fenders themselves. Waiting for the next installment.

[burkbuilds]

I got an e-mail today from the Trike kit place saying they'd take back the fiberglass kit and the wheels and they'd pay the shipping and refund my money on those items. I think that is about as much as I could have asked for under the circumstances.

The fenders arrived today, I think they will look and work fine and I also got some passenger floorboards so my wife will feel more comfortable if she rides 2 up with me.

Class time is eating up my evenings right now so I haven't done anything else to the bike yet. Hopefully this weekend will work out for me to have some time to get a lot done.

[Water Warrior 2]

That is good news. Now you don't have spare unneeded stuff cluttering up the shop. I would imagine your pics of the wild offset was a tip off that they need to rethink their design and offer to return your money with a much hoped for apology. I am glad things are looking better. Too bad the original set up wasn't botched because it would have been a nice looking trike.
On the other hand the new ideas are likely to be as good if not better. You might get more storage and/or flexability with a trunk and bags.
Question: how much does the charging system crank out? Any ideas about driving lights, heated gear power points and the like.

[burkbuilds]

http://www.vulcanforums.com/forums/show ... php?t=5212 (http://www.vulcanforums.com/forums/showthread.php?t=5212)
WW,
Here's a thread on the 900 and using heated gear. Basically, it's about like most bikes, with a 10 amp accessory load max (120 watts more or less). That's what I had on the 500 and I was able to run heated gloves and a heated jacket liner as long as I was at cruising speed, but if I was in stop and go city traffic I usually had to turn the thermostat down to keep from draining the battery. I wish bike designers would give us about double that accessory load ability but I'm sure they are trying to keep the price down and probably base their design on the average rider's needs and not many people ride in the cold when they need heated gear and such. I've noticed that you only seem to get a significantly larger output to handle lots of accessories on nice touring bikes like the Goldwing and similar bikes. How is your V-strom in that area, I bet you rode with some heated gear in your area didn't you?

I tried to find an aftermarket stator for the 500 that would put out more power but I was unsuccessful even though some suppliers claimed higher output. I bought one and metered it but it actually put out less wattage than the OEM one so I sent it back for a refund.
Eventually I ended up doing things to lower my power consumption like changing the running lights and turn signals to LED's. I looked into changing the headlight to an LED, but the cost was prohibitive, maybe that will change as the technology becomes more affordable.

[Water Warrior 2]

The latest GW's have an awesome charging system that rivals some small cars. Of course it only makes sense with all the built in electrical gear on the bike as standard equipment.
The Vstroms have an almost power supply. Only about 100 watts extra on mine but the newer ones(2007 and up) get a boost to 125 extra watts.
I have powered up heated grips, jacket, pants and insoles but not on a high setting. If that becomes needed it is too cold to ride with any comfort anyway. A medium setting on the TourMaster gear gets too warm if left on for any length of time so a low power level is almost perfect. The TourMaster gear is a great insulator and mostly I have worn it without power.
Oddly enough the bike with one of the larger charging systems has very little built in electrics for creature comforts. That is the Ural from Russia. I can only guess why they would have such a system. They don't need it for heated gear, they have Vodka for that. :lol:

[Water Warrior 2]

Calling BB. Calling BB. Are you still there?

Anybody heard from BB? I emailed him last week and no word yet. I'm starting to worry a bit.

[burkbuilds]

I'm still here WW. I've been busy with work, school and somehow I even managed to get the fenders and exhaust done on the Trike. It's going to the paint shop on Monday, yea! I'll try to post some pics this weekend. I'm taking my youngest daughter to a High School Football game in a few minutes and I have a lot of studying to do Saturday and Sunday but I think I can find enough time to at least post some pictures.

[Water Warrior 2]

Oh thank goodness. You had me wondering and thinking dark thoughts. Usually with your studies and family commitments you had time for a simple hello so I'm guessing there is a whole lot of priorities on your plate right now. Thanks for checking in. Now I feel much better.

[burkbuilds]

WW, I've had a few projects going at work that took a lot of my time and I somehow managed to get the fenders on but I just couldn't seem to find an hour or so to download everything and post updates, sorry.

When I realized the fiberglass body kit was not going to work, I opted for fenders and saddle bags to fill the space between the fenders and the bike. I wanted to make a support bracket that would be welded onto something solid, but I also did not want to weld near the bearings in the axle housing because the heat can really distort the shape of the steel and cause problems. I decided that the 1/2" plate steel that holds the brake calipers in place would provide an good place to weld to, and it bolts onto the axle housing, so I was able to remove it and do all my welding away from the bike and then just bolt it back in place.

http://s11.postimage.org/mxzcv2py7/P1020828.jpg (http://postimage.org/image/mxzcv2py7/)

I drew out a rough sketch of the brackets and then cut my pieces out with a porta band saw I borrowed from a neighbor. (It's nice to have neighbors like that.)
Each bracket was unique since I was having to deal with that wheel offset situation. One had to move out away from the caliper plate and the other needed to move in from it.

http://s16.postimage.org/6kumkeh0h/P1020832.jpg (http://postimage.org/image/6kumkeh0h/)
Once I got them welded I used a grinder to smooth up all the welds and then sanded and cleaned everything and degreased it. I then sprayed them with a self etching primer I've decided I like to use more than the standard grey primer. It just seems to bond better and it lays down nicely.

http://s14.postimage.org/5sb0bisgt/P1020837.jpg (http://postimage.org/image/5sb0bisgt/)
I then used a Rust-O-leum auto paint and painted everything black before mounting it to the bike.

http://s18.postimage.org/an1fuvw45/P1020839.jpg (http://postimage.org/image/an1fuvw45/)

http://s16.postimage.org/u5kwd5xgh/P1020841.jpg (http://postimage.org/image/u5kwd5xgh/)
I ordered fenders from a trailer supply and welded pre-cut backing plates to the back of each fender. Once I got everything welded up and ground down smooth I primed them with the same self etching primer and then used truck bed liner to coat the underneath side so they wouldn't get dinged up easily and start rusting on me.


http://s11.postimage.org/ejflcmggv/P1020830.jpg (http://postimage.org/image/ejflcmggv/)

http://s10.postimage.org/vqcn7pm4l/P1020829.jpg (http://postimage.org/image/vqcn7pm4l/)

http://s8.postimage.org/9d5ymjn6p/P1020831.jpg (http://postimage.org/image/9d5ymjn6p/)
I pre-drilled mounting holes in the brackets so I could use those holes as a guide to mark the fenders for drilling. Then I bolted them on using Stainless steel bolts and acorn nuts on the inside towards the bike. These are definitely just some "plain jane" fenders but they should do the job. One of my neighbors builds custom bikes and after he saw this sitting in my driveway today he offered some great ideas on making those fenders really cool. He showed me how I could have cut the back side flange and bent the radius in so it would have "hugged" the tires better and he also suggested ways to make them dressy by cutting a pattern shape in the front and back of each fender. Great suggestions, and if he'd made them before I got this far along I would have done that, but at this point I'm not willing to undo all that work, so these will just stay plain.



http://s8.postimage.org/ge356t3q9/P1020847.jpg (http://postimage.org/image/ge356t3q9/)

http://s10.postimage.org/bgxpbjeit/P1020848.jpg (http://postimage.org/image/bgxpbjeit/)
I got my wife to snap a shot of me sitting on the bike after I got the fenders on.

http://s9.postimage.org/5a4bm0ph7/P1020854.jpg (http://postimage.org/image/5a4bm0ph7/)
I think I may change the exhaust system later, but for now I bought some 12" "Mufflers" and welded them on and then put the OEM Chrome shields back in place. Kinda loud but the mufflers were cheap ($58 Pair) and I am chomping at the bit to get riding again.


http://s9.postimage.org/cnori3fuj/P1020865.jpg (http://postimage.org/image/cnori3fuj/)

I took some time this morning and put about 20 miles on her riding around the area. I ran it up to 70 mph on Highway 27, and toured through part of the Chickamauga Battlefield, spotted about 30 dear grazing around the road. Three of them came on across the street right in front of me, but I spotted the buck and slowed way down while the doe and fawn followed him across. The rest of them just turned and stared me down as I went on past them. I'll have to put some major hours on this thing before I feel as comfortable on it as I did on two wheels. It will take some getting used to turning the handlebars to go around curves and it shakes me a lot more going over bumpy roads than the bike did, but overall it was great to be back out riding with the wind in my face and the bike underneath me. :2tup:

[Water Warrior 2]

Oh yeah, you have been busy. Lots of progress. Nice looking wheels and the plain Jane fenders should look nice after the painting. Question, how was the braking with the 2 rear discs on your test ride? I would think it would be pretty affective with the added weight and car tires. In the future will you be changing the rear signals to a wider position on the rear? A fender mounted tail light/signal might be nice on each side. Question, have you had any ideas about using the open space under the center rear fender. Maybe a storage box/area for emergency stuff while on tour/longer rides. Thought I'd ask but I think you have that covered in your plans.
Great pics of course. Best one is the guy sitting astride the trike. You look good on it.

Now go back to your studies and leave me hanging. lol. :lol: :lol:

[northsidegz]

That looks nice! Enjoy!

[burkbuilds]

Thanks guys. The braking really didn't feel a lot different to me. I was expecting it to be significantly better with two rear disks but since they are physically smaller than the single OEM rear disk I guess it all evens out. I am planning to add LED rear brake/running/signal lights to the rear fenders. I already have them and I need to drill some holes for the wiring and mounting today before I take it to the paint shop on Monday. I also plan to add yellow reflectors to the front of the fenders so oncoming traffic will be able to see how "wide" I am at night.

I had not thought about using the area under the center rear fender for storage. I like that idea, especially for tools or something like that. I'll have to give that some thought.

I originally had the OEM saddle bags mounted but they rubbed the inside of the fenders so I pulled them off and ordered some that are about 2" less in width. They should be in by the time the bike comes back from the paint shop.

When it gets all painted up I'll post some final pics.

[alantf]

I already have them and I need to drill some holes for the wiring and mounting

Have you given any thought as to how you're going to run the wiring back to the bike? It'd really spoil the look if the wiring was showing. Chrome tube perhaps? Or have you got another route? :)

[Water Warrior 2]

BB, a word of caution about the LED rear lights. Test them for brightness before doing and fender cutting/drilling. I have seen some that are more show than actual functional lights for a road worthy machine. Test them outside in sunlight where they will be used to determine if the lights are adequate. Really good LED front/rear lights are not cheap. The best solution in my world would be to use DOT trailer lights from an auto parts store. I actually have a 3.25 in round DOT LED trailer tail/brake light as an extra on the Vstrom. The aftermarket has a zillion really good looking lights but most lack any real visibility content.

Whelan is the company that produces LED lights for police cruisers and they really work.

[burkbuilds]

Thanks guys good advice. Although I do not plan on removing the OEM tail lights so anything will be an improvement over nothing. I'll definitely run them before installation. They should be pretty bright, I think they have 15 LED's in each assembly and they were not cheap. But I haven't actually tested them yet.

As for running the wiring, I have some 3/8" round tubing that I plan to thread and mount between the OEM fender and the new fenders to run my wiring inside. No visible wires and protection as well. I'll paint them black and they should just blend into the saddle bags and framework visually.

I was planning to get this all finished tonight, but I just now got all my homework done and turned in electronically and I'm bushed, so the holes may have to wait until after the paint job. Not what I intended but probably what is actually going to happen now.

[Maggie]

You look awesome on the trike BB! I imagine the feeling is similar to getting used to riding with a sidecar.

[burkbuilds]

Maggie, do you have a sidecar? I've never ridden with one, but a good friend of mine had a BMW with a side car for many years. He always said it took a lot of getting used to. I'm still waiting on the paint shop to finish up. Hopefully they will get done sometime next week.

[Water Warrior 2]

With a sidecar the biggest difference is the steering input as far as I know. A friend has a Ural rig and loves it. After a lifetime of 2 wheels he was caught out with his natural memory muscles and 2 wheeled experience. It only took 15 minutes to crash and go over the bars. He zigged when he should have zagged.
Many sidecars do not have a brake so the bike will try to swing left when braking and turn right when accelerating due to the weight. The Ural does have a sidecar brake that is adjustable to compensate for any added weight. The sidecar must also be properly aligned with the bike or it will not track properly and be a real handfull to ride safely.
My friend Don now has his second Ural(2 years) and is more than happy compared to the 1st(3 years) one due to alignment and quality control issues. He quite often just loads up the sidecar and disappears for weeks on end.

[Maggie]

Maggie, do you have a sidecar? I've never ridden with one, but a good friend of mine had a BMW with a side car for many years. He always said it took a lot of getting used to. I'm still waiting on the paint shop to finish up. Hopefully they will get done sometime next week.

No BB, I don"t but I sure do lust for one! We have a local guy pretty well known for his sidecars..."sidecar Doug." I always see him tooling around and have chatted with him many times. One day... You know, the idea of a red sidecar with a beautiful Dalmatian riding along with me wearing his Doggles... :2tup:

[Water Warrior 2]

Maggie, do you have a sidecar? I've never ridden with one, but a good friend of mine had a BMW with a side car for many years. He always said it took a lot of getting used to. I'm still waiting on the paint shop to finish up. Hopefully they will get done sometime next week.

No BB, I don"t but I sure do lust for one! We have a local guy pretty well known for his sidecars..."sidecar Doug." I always see him tooling around and have chatted with him many times. One day... You know, the idea of a red sidecar with a beautiful Dalmatian riding along with me wearing his Doggles... :2tup:
Talk to him about the pros and cons of a sidecar. Maybe he can give you some leads to a cheaper sidecar without going broke. Then you can afford to feed the dog.
You might try lurking on sidecar rig forums. Hmm................I have a new thing to search for now. Knowledge is power as they say.

[bpdchief]

Your bike is looking GREAT!!! :2tup: Maybe building trikes will become a part time money maker for you

[burkbuilds]

Still waiting on the paint shop. I talked with the owner yesterday and he asked me if those were trailer fenders I'd put on the bike. "Yes they are", I told him. He told me that when he gets done with them they will look like motorcycle fenders. I'm not exactly sure what he's doing, but this guy is really good and really creative. My wife said, "Ca-ching, ca-ching" when I told her what he said. I hope this doesn't bankrupt me. I'll be eager to see what he's done with the Trike. Hoping to get it by next weekend.

[Water Warrior 2]

Oh crap. Now I have to wait even longer than I expected. We are leaving for a couple weeks on Tuesday or Wednesday. But as they say "Good things are worth waiting for." We will be back near the end of October.

[burkbuilds]

WW, hope you have a great trip. Hopefully, when you return I will have pictures of the finished product for you to see.

[Water Warrior 2]

WW, hope you have a great trip. Hopefully, when you return I will have pictures of the finished product for you to see.
Thanks BB. I'll try for some vacation pics to show you.

[burkbuilds]

Well, it is still in the paint shop. They are almost done, everything is painted and has at least one clearcoat on it and once he finishes the next clear coat he's going to pin stripe it and I can pick it up, he promises, Friday, this Friday. I hope.

Here are two pics I snapped this afternoon when I stopped by to see the progress.

http://s17.postimage.org/4u4dv5kez/P1020870.jpg (http://postimage.org/image/4u4dv5kez/)

http://s8.postimage.org/v5caxpyoh/P1020871.jpg (http://postimage.org/image/v5caxpyoh/)

I have to admit the paint looks as good as the factory paint, but it has taken a while to get it done.

[Water Warrior 2]

Looking good BB. With luck you will have the final wiring etc done this weekend and be on the road. And then comes the road report........hint hint.

[Rookie Rider]

Looking good there bb...........im talking about the bike ya know :)

[burkbuilds]

I finally got the Trike back from the paint shop late yesterday afternoon (Friday November 10th). This morning I started putting things back in place like the passenger backrest, the chrome luggage rack, crash bars and such. It's supposed to hit the low 70's here today and tomorrow so I hope I get everything back together and ready to ride by this afternoon. Here are a few shots of the progress:

http://s10.postimage.org/ud1x4ebv9/P1020873.jpg (http://postimage.org/image/ud1x4ebv9/)

http://s13.postimage.org/fmtsi5o0z/P1020872.jpg (http://postimage.org/image/fmtsi5o0z/)

http://s18.postimage.org/y4mp9l6b9/P1020874.jpg (http://postimage.org/image/y4mp9l6b9/)

http://s9.postimage.org/y5q2leliz/P1020880.jpg (http://postimage.org/image/y5q2leliz/)

http://s10.postimage.org/iuktb08t1/P1020881.jpg (http://postimage.org/image/iuktb08t1/)

http://s7.postimage.org/4bd9j653b/P1020875.jpg (http://postimage.org/image/4bd9j653b/)
The last shot is just a close up of the fender paint. This guy is the best I've seen, this looks exactly like the factory paint job on the rest of the bike. I had to wait a long time for him to get it done, but it is a really great paint job. The colors match perfectly it has several clear coats on it and the pin stripes are arrow straight. I miscalculated the amount of pin stripe material it would take so I have to order one more stripe to do the trunk and then it will be completely done. :2tup:

[Water Warrior 2]

As I was logging on my thought was "Oh boy oh boy oh boy BB will have pics." And there you are!!!! Absolutely stunning final transformation. The bike is beautiful with the rest of the equipment installed. The paint is perfect.
Granted it has been a long hard build but something to be very proud of and do a little bragging about. Get out there and ride that sucker.

I'll bet a dollar Mom likes her new mobile Throne. :2tup: :2tup:

[alantf]

Beautiful trike, and a tribute to your skill. Don't mean to be picky :) but looking at the rear end, do you think that the turn signals might be better if you had a set to match your new tail lights, or even a set of red/orange tail lights/turn signals on the fenders? Something about the old ones seems to offend the aesthetic beauty of the trike. :) :) :)

[bpdchief]

Beautiful bike!! :2tup: You have done an amazing job.

[burkbuilds]

Thanks guys, and yes Alan I think there is always room for improvement on just about everything, well, maybe everything except my mom's chicken and dumplings. :)

Right now though I think I'm just going to ride for a while. I've been off the bike since I wrecked back on April 15th other than the 50 miles I've put on it driving back and forth to the paint shop and a couple of short trips to make sure things were working correctly mechanically.

I put the wheels back on this evening, went for a little ride around town and she's parked in the driveway now ready for me to get on when I leave for work in the morning.

I missed all my favorite riding weather. It's supposed to be in the 30's in the morning here and probably won't be back near 70 for a while now unless we get an unusually warm spell. Global warming where are you?

Don't get me started.

Ready to enjoy riding now. :)

[burkbuilds]

It's Friday evening and I've had a full week of riding on the trike now. I'm enjoying being back in the saddle again. Filled up the tank tonight after work and got 41 mpg around town which is about what I was expecting. No where near the mpg's I got on the GZ250 or even on the Vulcan 500, but a lot better than my 81 F100 :)

I miss leaning into the curves and it's a bit more work steering the Trike than I expected, but all in all I'm glad to be back in the open air, smelling the fragrance of nature and feeling the air on my face :2tup:

I've already had offers to buy the trike and several people have asked for a ride, including a little old man I met at physical therapy :)

[Water Warrior 2]

Good to hear you are happy with the trike. For sure 3 wheels feel different than 2 wheels but you will enjoy it all the same. Must nice to not have to put your feet down at a stop.

[burkbuilds]

I've been riding the Trike for about a month now, pretty much every day to work and a few short rides on the weekends. I got my mom, my youngest daughter and even my wife to ride 2-up with me. There are certain advantages to the Trike. It is amazingly stable, I'm not really concerned with hitting gravel in the road way, or slick things like manhole covers in the rain, and you never need to put your feet down at a traffic light or in stop and go traffic. It actually has a very tight turning radius and I can take turns at relatively high speeds and it sticks to the road like it was on a rail. Having said that, I really miss leaning in the turns and being able to avoid most of the potholes and such that you just can't seem to miss on a Trike. I also don't like "hanging on" in the turns because of the lateral g-forces. If I had a hip replacement or some physical reason I could not hold a bike up at a stop or if I felt like I wouldn't be able to raise it if I dropped it then the Trike would be significantly better than riding in a cage (car). But, I have healed up enough from my accident last April that those things no longer apply to me. So, I think I'm going to convert it back to two wheels and just sell the rear axle kit and the fenders to someone that wants to give it a go converting their 900 to a trike.

Merry Christmas everyone. :D

[JWR]

Best of luck, doing it your way.

You really have some amazing skills.
:2tup:



Jerry

[blaine]

Glad to see you want back on two wheels.Best of luck in the new year.Merry Christmas to you & yours.
:) :2tup:
http://s10.postimage.org/493asxjv9/Chopper_Emo.gif (http://postimage.org/)

[Water Warrior 2]

Wow BB. I am surprised. I guess the decision to go back to 2 wheels was not an easy one. Although you put a lot of work into the trike conversion and it's trials it was also a tribute to your determination and steadfastness.
I doubt there will be much of a problem selling the trike kit once some one sees your results and knows it will fit a 900 with all the mods made for a proper fit.
Glad as all get out to hear you are in fit condition to go back to 2 wheels. I think that is a really big +. Best news of all.

[mrlmd1]

Why not sell the whole thing - wouldn't that be better, and then get another bike? Or at least don't take it off 'till somebody can ride it and see how the trike kit performs?

[bonehead]

BB, I have an idea. Keep the trike for the future and go get another 2 wheeler for the now!

[burkbuilds]

Sorry for taking so long to reply. I've been a little busy. My middle daughter graduated college yesterday, I graduated today and other daily things have kept me busy.

I have several options I could choose with the Trike/bike. At this point, I'm just ready to get back on 2 wheels again soon and the fastest way I can do that is to just put everything back the way it started and sell the trike kit if possible. If I wait and try to sell the whole trike, then it could take months and I'm just not willing to do that right now. I can't afford to sit on this one and buy another one either, so I am planning to convert back to two wheels and take my lumps on selling the kit on ebay or something.

[Water Warrior 2]

Congrats to you and your daughter. Must be a wonderful feeling after all the hard work and studying for both of you.

Selling the trike kit is likely your best/quickest option to get back on 2 wheels. With the documention and final results in pics etc you will have proof for the next owner of a 900 who wants a triked 900 with no hassles. You fixed the flaws and made things work as they should. Hopefully some one will be willing to appreciate the amount of thought and work you put into the project and reward you handsomely.

[burkbuilds]

Thanks WW, you have been a great encouragement to me in a lot of areas, from my education to my recovery from my wreck, and while I was building the trike. I really appreciate all the kind words and thanks again for the congratulations on my daughter's and my graduation. That makes it two daughters with college degrees finished and one to go.

It was a little surreal today walking across the stage, shaking hands with the regents and getting my degree. I don't think I've smiled that much since I got married over 28 years ago. It was a lot of hard work and there were lots of times I wondered if I was going to make it, but I just kept putting one foot in front of the other and telling myself that I knew a lot of people with college degrees that couldn't possibly be any smarter than I am, so it must be possible for me to earn one too. Finally, today, I made it. It's a pretty good feeling. :2tup:

I'm glad I tried the trike. It gave me something to focus on during my recovery, it made my wife happy that I gave it a shot, and now I know for sure that three wheels just doesn't "do it" for me the way two wheels do. Besides, I like building things and I get a real feeling of accomplishment anytime I make something, so the Trike build was one of those deals for me. I'll probably loose money on it, but I gained other things from it that are often of more value than money is to me.

I also found that I really like the Vulcan 900. At 6'1" tall it's a better physical fit for me, giving me more leg room and it just feels "right" when I'm seated on it. It has a very low center of gravity and handles really easily and there is a lot of torque in that motor, so you don't need to downshift as much as I needed to on the 500 and the 250. I enjoyed the little bit of riding I got to do on it before I converted it to a Trike and I'm looking forward to riding it again as a two wheeler.

[Water Warrior 2]

BB, you are the inspiration to a lot of us. You make a wonderful role model for others to look to for a sense of what can be done when the chips are down.
You started small on 2 wheels, commuted back and forth in all kinds of weather and proved it could be done. Fast forward through a couple more bikes and the mods you shared with us. All while going to school and raising a family. To say the least your plate was full to capacity.
Your crash and many injuries were pretty frightening with no real assurances of a total recovery. BB, you turned my thoughts 180 degrees with your enthusiasm and will to succeed where I likely would have thrown in the towel. You turned a negative into a big positive to keep your self busy and recover at the same time.
Now you will soon be back on 2 wheels with a diploma in the back pocket to remind you that nothing is impossible. I wish I could shake your hand and congratulate you in person. nuff said.

[JWR]

Well said, WW.


:2tup:

[PimpS]

BB, congrtulations on your diploma, overall success as being a good father and your motivational vitalism. I'm just lurking for past few months, but Vulcan 900 Trike Build is the thread i like and always read. Whole thread is a story about not giving up, searching for the options when odds are shitty... The best i like the fact of you being sincere to yourself and going back on two wheels, I dig you, 2 wheels are wheels, and kawasaki is kawasaki.
RESPECT TO YA!

Primoz

[burkbuilds]

Thanks everyone, I am overwhelmed by your kind words.

Merry Christmas. :2tup: :)

[Maggie]

Wow, so much to catch up on in the few months I have not been reading the boards! Congratulations BB!!! For your degree, for your family support and their successes and, most especially for your physical recovery. You truly are such a positive influence for me and so many others! :rawk:

[burkbuilds]

Thanks Maggie and Happy New Year to you as well. :2tup: